Design Modification And Steady State Thermal Analysis Of Cylinder Fin Body With Different Cross-Sectional Fins Using Ansys Software

Abstract

Thermal management is a critical aspect of air-cooled internal combustion engines because excessive heat generation during combustion can adversely affect engine performance, fuel efficiency, durability, and operational reliability. Cylinder fins are commonly employed to enhance heat dissipation by increasing the surface area available for convective heat transfer. However, conventional fin geometries often fail to provide optimal cooling performance under varying operating conditions. Therefore, the design optimization of cylinder fins has become an important area of research in automotive and thermal engineering applications. This study investigates the design modification and steady-state thermal analysis of engine cylinder fin bodies with different cross-sectional fin geometries using ANSYS Workbench software. Four fin configurations, namely cylindrical, rectangular, aerodynamic, and curved fins, were modelled and analysed under identical thermal and airflow conditions. Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) techniques were employed to evaluate airflow characteristics, temperature distribution, heat transfer coefficients, and heat flux behaviour. The simulation results indicate that fin geometry has a significant influence on thermal performance. Heat transfer coefficients of 681 W/m²K, 683 W/m²K, 688 W/m²K, and 696 W/m²K were obtained for cylindrical, rectangular, aerodynamic, and curved fins, respectively. The curved fin demonstrated the highest heat transfer capability due to enhanced airflow turbulence and improved air-fin interaction. Furthermore, heat flux increased consistently with increasing inlet air velocity, confirming the effectiveness of forced convection cooling mechanisms. Comparative analysis revealed that modified fin geometries significantly outperform conventional cylindrical fins in terms of temperature reduction and heat dissipation efficiency. The aerodynamic fin exhibited improved airflow distribution and reduced flow resistance, while the curved fin achieved superior cooling performance by promoting turbulence generation around the fin surfaces. The findings of this research demonstrate that optimized fin geometries can substantially improve engine cooling efficiency, reduce thermal stresses, and extend component life. The study also highlights the effectiveness of ANSYS-based simulation methodologies in evaluating and optimizing engine cooling systems prior to manufacturing. The proposed design modifications provide practical and economical solutions for developing advanced air-cooled engines with enhanced thermal performance and operational reliability.